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Confidential © Siemens Energy, 2020Siemens Energy is a registered trademark licensed by Siemens AG.
Siemens Gas and PowerOverview of additive manufacturing, benefits and challenges
industrial approach for AM
Pajazit Avdovic PhD, Senor Key Expert AM
Additive manufacturing in nuclear energy applications
2020-09-23
Pajazit Avdovic | SE GP I SV TI AM ID
Confidential © Siemens Energy, 2020
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
Siemens Gas and Power
Turbine manufacturing in Finspong since 1913
Part of Siemens since 2003
2020 Siemens Energy AB
approx. 2,600 in Finspong & 100 in Trollhattan
Since the start in 1913, we have sold 1000 gas turbines, ~ 2,300 steam turbines and ~ 50 power plants
95% is exported and in more than 100 countries there 90% with service agreements
Pajazit Avdovic | SE GP I SV TI AM ID
Confidential © Siemens Energy, 2020
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
Additive Manufacturing at Siemens Energy AB
Pajazit Avdovic | SE GP I SV TI AM ID
Confidential © Siemens Energy, 2020
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
Additive Manufacturing at Siemens Energy AB
Pajazit Avdovic | SE GP I SV TI AM ID
Confidential © Siemens Energy, 2020
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
Additive Manufacturing at Siemens Energy AB
Pajazit Avdovic | SE GP I SV TI AM ID
Confidential © Siemens Energy, 2020
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
Gas turbines with it’s complex parts in expensive material
and
relatively small volumes makes AM very attractive!
Additive Manufacturing at Siemens Energy AB
Pajazit Avdovic | SE GP I SV TI AM ID
Confidential © Siemens Energy, 2020
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
2019
SGT-800
Heat shield
2018
SGT-700
Burners
Commercial
operationOu
tco
mes
Key e
nab
lers
FY
SLM: Selective Laser Melting
From R&D to serial parts production with SLM technology in 10 years
2006
Material
Solutions
founded in
the UK
First
Selective
Laser Melting
demonstrators
2012
Installation
of 1st EOS M280
SLM machine in
FSP, specifically
adapted for Burner
repair
2013
First
SGT-800
Rapid Burner
Tip Repair
SGT-750
combustion
swirlers in
commercial
operation
2014
Dedicated
Additive CoCs
established
Develop-
ment and
qualification of
Processes and
Materials
2017
Turbine
blade printed
& tested
in engine
(SGT-100)
2009
Installation
of the 1st EOS
M270 SLM
machine in
FSP
2015
Prototyping
of qualification
parts for LGT,
IGT, AGT, IST
First
M400/4
Installed New M400/4
Shared
modules
Installed
New workshop
…
Blades
Vanes
Ring Segment
SGT-1000F
Burner head in
commercial
operation
2016
Acquisition
Finspong
Industrial
workshop
inaugurated
Siemens was an early adopter of SLM AM technology and have successfully scaled its production
Pajazit Avdovic | SE GP I SV TI AM ID
Confidential © Siemens Energy, 2020
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
Siemens Gas and Power is one of the world leaders in designing and producing commercial AM components for serial production
Siemens Gas
and Power’s
experience
covers today
more than…
40+3D printing machines operational worldwide
Over
10 years
experience of SLM
20+components already
commercially implemented
>1 500 000operating hours on Siemens turbines
150+specialized engineers
200components identified
for AM until 2025
Energy AutomotiveAerospace Tooling & processing
3rd party
business
Pajazit Avdovic | SE GP I SV TI AM ID
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
Why Siemens Gas and Power works with Additive manufacturing
• Fast technology validation &
product development on demand
• Shortened process development
• Overall lead time reduction
• Mitigate single source situations
on e.g. mature parts
• Reduction of assemblies to one
component
• Small batch sizes & different
parts in one build job
• Reduced emissions through
improved fluid mixing, e.g.
complex nozzle designs
• Reduced waste from alloys
• New geometries
• Better heat transfer & cooling
• Improved efficiency & power
output
Innovative
Designs
Environment
Benefits
Supply Chain
& Reduced
Complexity
Time-to-Market
& Lead Time
Reduction
75%Reduction of
development time
65%Less resources
in production process
30%Reduction of greenhouse
gas emissions*Flexibility for
design of parts
Pajazit Avdovic | SE GP I SV TI AM ID
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
What benefits are enabled by Additive manufacturing for the customers?
• Possibility to store parts digitally
in databases –as Digital Twins -
instead of a physical storage
• Sourced parts on demand
located near the source of need
• Minimum order quantities since
AM allows for economical
production in small units
• Minimizing inventory costs for
working capital, warehousing,
and obsolescence
• Possibility to order obsolete part
through AM reversed
engineering (in consideration with
IP rights) instead of keeping the
parts on stock
• Reduced company carbon
footprint through e.g. less material
waste and reduced transportation
of parts
• Improved design for better
efficiency & power output
Environment
Benefits
Supply Chain
benefits
Spare parts
on demand
90%Reduction of
lead time
60%Faster
repairs
Obsolescence
management
Possibility to manufacture
obsolete parts
Reducing
CO2 emissions
Pajazit Avdovic | SE GP I SV TI AM ID
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
Our Unique Selling Propositions – Outstanding in the field of metal Additive manufacturing
Aim at highest quality
Test and implementation
according to highest standards
(AS 9100, ISO 9001, Nadcap)
Unique capability
One of the market leader for most difficult high-temperature alloys and an extensive material database for most common nickel based alloys
Proven references
More than 1 500 000 operating hours in commercial operation and high performance parts in various industries
Complete service
Offers within complete value chain from consulting and training to manufacturing and post-processing
Pajazit Avdovic | SE GP I SV TI AM ID
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
Gas turbine focal areas for Additive Manufacturing today
Turbine
Small parts
Blades and Vanes
Combustion System
Burner / Swirler / Nozzle / Mixer
Compressor
Small parts
Pajazit Avdovic | SE GP I SV TI AM ID
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
Key factors and technologies in the development of future gas turbines
• Increase of mass flow
• Increase of pressure ratio
• 3D aerodynamics optimization
• Reduction of aerodynamic losses
Compressor Combustion
• Higher combustion temperatures
• Optimized burner (fuel flexibility)
• Reduced emission
• Increased efficiency
Turbine
• Higher turbine inlet temperatures
• New materials and coatings
• Improved cooling and sealings
• 3D aerodynamics, loss reduction
Additive manufacturing considerably reduces timeframes to reach goals
Pajazit Avdovic | SE GP I SV TI AM ID
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Fields of use and application
Rapid Repair
▪ Product: SGT-700/800
▪ Component: Burner tip
▪ Benefit:
− 90% lead time reduction
▪ Status: In commercial
application since 2013
Spare parts on
demand
▪ Product: SGT-1000F
▪ Component: Burner head
▪ Benefit:
− Reduced lead time
by up to 40%
▪ Status: In commercial
application since 2016
Rapid Prototyping
▪ Product: SGT5-4000F
▪ Component: Turbine Vane
▪ Benefit:
− Development time
reduction by 75 %
− Early validation of
NextGen Designs
▪ Status: Tests ongoing
Rapid Manufacturing
▪ Product: SGT-700/800
▪ Component: Burner
▪ Benefit:
− Higher performance
− 85% lead time reduction
▪ Status: Final testing phase
Pajazit Avdovic | SE GP I SV TI AM ID
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
AM challenges and opportunities
Challenges• Material knowledge
• Design culture
• Stand-alone software
• Training
• Machine performance
• Quality issues
• Health and Safety concerns
Disappointment:
”It is not just 3D-Printing!
It is much more complex..”
2020+2009
Innovation triggerPeak of inflated
expectations
Plateau of
productivity
Slope of
enlightenment
Trough of
disillusionment
201820162015
Connected AM
Connected” through MES, AM Network, Digital Twin and Use Build Job
Simulation
Learning AM
“Learning” through Big Data Analytics, AM Monitor, Virtual
Storage and Machine Learning
Intelligent AM
“Intelligent” through Robots, VR/AR, AI
Autonomous AM 2025 +
IoT for AM
Traditional AM
Pajazit Avdovic | SE GP I SV TI AM ID
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AM burner manufacturing for flexibility, shorter lead time and improved lifetime
Conventional
• 13 parts / 18 welds
• TBC on front
• 26w lead time
SLM burner
• 1 integrated part
• No TBC due
• 3w lead time
• Manufacturing of SGT-700 / 800
burners by means of SLM
• Redesign of existing burners for
SGT-700 / 800 to utilize the
design freedom offered by SLM
• Full scale engine test performed
• Commercial operation in 2018
Approach Benefits
• Reduced lead time by
23 weeks
• Enabling customization
for fuel flexibility
• Removal of TBC
Pajazit Avdovic | SE GP I SV TI AM ID
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
Our references – First 3D printed water pump impeller is successful commercial operation at nuclear power plant
Challenges
Obsolete part, since the original
supplier no longer existed
• Experts at Siemens Slovenia reverse
engineered the impeller to produce a
"digital twin" that served as the basis for
the 3D printing technique
• Assured qualification of part with high
safety and reliability requirements
Solution
• Possibility to re-produce an obsolete part
• Lead time reduction for parts replacement
• Saving of material
• Eliminated tools
• On demand
Customer
Benefits
Customer Nuclear Power Plant Krško
Country Slovenia Obsolete part
Reverse
engineering and
qualification of
high
requirements
Significant
lead time
reduction
Pajazit Avdovic | SE GP I SV TI AM ID
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
Our references – Two oil sealing rings installed as replacement parts in a SST-300 industrial steam turbine
Challenges
Adaption of the components to
customers challenging environment
and needs
• Siemens engineered, designed and developed
the part as part of a collaborative project between
Siemens experts in Germany, India and Sweden
• Optimized performance that could not have been
achieved only with traditional manufacturing
processSolution
• Specific changes with high impact in the design
leading to improved functioning of the oil sealing
ring
• Printed oil sealing ring in one single step
• Saving of material and reduced weight by
approximately 80 percent due to the use of
aluminum and the weight-optimized design
• Significantly reduced lead-time
Customer
Benefits
Challenging
environment and
need of the
customer
Optimized
performance by
Additive
manufacturing
Reducing weight
by Additive
Manufacturing
CustomerJSW Steel Ltd. plant in
Salem
Country India
Pajazit Avdovic | SE GP I SV TI AM ID
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
Our references – Titanium high pressure hydraulic manifold Maximum availability for passenger aircraft
Challenges
• Maximum availability and safety
requirements
• Light weight and long lasting design
• Proof of long-term functionality
• Combination of advanced Additive Manufacturing
technologies from a variety of business fields
• Unique design features technical requirements
• Optimized performance that can only be
manufactured using Additive Manufacturing
• Tested under extreme conditions (Max. 5,500 psi
/ 379 bar for 2,000,000 cycles)
Solution
• Fulfilling most demanding requirements by
Aerospace industry
• Highest availability for maximum passenger
safety
• Accelerated technology validation delivered by
expertized one-stop shop
Customer
Benefits
Most demanding
requirements by
Aerospace
industry
Innovative
design for
Additive
Manufacturing
Additive
Manufacturing in
high quality
materials
CustomerSumitomo Precision
Products Co., Ltd.
Country Japan
Pajazit Avdovic | SE GP I SV TI AM ID
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
Our references - Additively manufactured and tested gas turbine blade in Alloy 247, major breakthrough
Shortened lead time by
75%
3D-printing use case or application
Siemens awarded by ASME for
3D-printed gas turbine blades
Siemens, Superalloy gas turbine
blades – winner
Travels over
1,000 mphReduced costs by
70%
Surrounded by gas at
1,250 ºC
Improved efficiency by
0,1%
Pajazit Avdovic | SE GP I SV TI AM ID
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
• Reliable supply chain partner for
prototype and serial production of AM
components in adjacent industries
• Consulting, engineering and
manufacturing services tailored to
customer needs
• Leading user of metal AM
components for power generation
assets
• Dedicated research & development
budget
Energy AutomotiveAerospace Tooling & Processing
3rd party
business
Siemens Gas and Power – Additive Manufacturing Providing customer value through manufacturing and service
Pajazit Avdovic | SE GP I SV TI AM ID
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
Our Unique Selling Propositions – Proven references
Unique capabilityOne of the market leader for most difficult high-temperature alloys and an extensive material database for most common nickel based alloys
Six fully qualified AM
materials available in
Siemens design systems
More than 10 years
experience in high
temperature metal AM
Extensive materials
database
Materials & technology
roadmap in place
Experienced with difficult
to weld alloys
Dedicated research &
development budget
Pajazit Avdovic | SE GP I SV TI AM ID
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
Unique capabilityOne of the market leader for most difficult high-temperature alloys and an extensive material database for most common nickel based alloys
Qualified print process
Readily weldable
Nickel Superalloys
• Haynes 230
Aluminum
• A20X
Difficult to weld
Nickel Superalloys
• CM 247 LC
• In 738 LC
• C 1023
• MAR M002
Ferrous alloys
• SS 17-4
• SS 15-5
• SS 304
• SS 316L
• Duplex 2205
• Maraging Steel M300
Cobalt alloys
• CoCrMo
• MAR M509
Titanium alloys
• Ti6Al4V
Fully qualified with design data
Nickel Superalloys
• In 939
• Haynes 282
Cobalt alloys
• Merl 72
Nickel Superalloys
• Hastelloy X
• C 263
• In 625
• In 718
Our Unique Selling Propositions – Unique capability
Pajazit Avdovic | SE GP I SV TI AM ID
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
Aim at highest qualityTest and implementation
according to highest standards
(AS 9100, ISO 9001, Nadcap)
• AS9100: ISO 9001
• International AM committees; ASTM, ISO
AM, Oil & Gas, Maritime
• Ongoing roadmap e.g. AMS 7003, Nadcap
M&I & ISO 17025
• Nadcap AM
• Machine qualification
• Full product qualification (e.g. Siemens PPQ)
• Job/machine specific trials (full scaling, partial
scaling, feature trials)
• Large Gas Turbine components qualified less
than 10 weeks
One of the industry
leading within Quality
Assurance
Validation and
Qualification
Our Unique Selling Propositions – Aim at highest quality
Pajazit Avdovic | SE GP I SV TI AM ID
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
Metrology and scanning
Metrology, scanning and
digitization of your spare parts
Training
Training and consulting for
your projects by experts
Manufacturing
Manufacturing and post-
processing for prototypes and
small series production
Complete service
Engineering
Engineering and reengineering,
design optimization of parts for
additive manufacturing
Offers within complete value chain from consulting and training to manufacturing and post-processing
Our Unique Selling Propositions – Complete service
Pajazit Avdovic | SE GP I SV TI AM ID
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
One of the largest Metal AM Printer fleets in the world
EOS M400-1
EOS M400-4 &
EOS M400-4 Shared
Modules
• 4 laser
• 400x400x400 mm
▪ Ultrasonic Cleaning
▪ 5 Axis Machining
▪ Blasting
▪ EDM Cutting/Bandsaw
▪ 3D GOM Scanning
▪ CMM
▪ Heat treatment
▪ Brazing
▪ Flow testing
▪ Coating
EOS M280
• 1 laser
• 250x250x325 mmCustomized for repair –
printing on top of base material
EOS M270
• 1 laser
• 250x250x325 mm
EOS M290
• 1 laser
• 250x250x325 mm RenAM 500Q
Printers Post processing
+Siemens
Supplier-base
for complete
production of
parts
Additive Manufacturing Printers and Post Processing ability
Pajazit Avdovic | SE GP I SV TI AM ID
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Leading user of AM Technology to internal and external customers
Leading user of Software & Automation solutions
• Digital end-2-end chain
with NX12
• AM Monitor
• Control systems
• IoT Cloud solutions (Part
Manufacturing Platform)
• Mindsphere, Teamcenter
• MES, SCADA
Software & automation
AM for new products• AM for GT hot gas path components
AM for maintenance, repair
& obsolete parts
AM for prototyping and R&D
AM for tooling
Siemens is leading the Industrialization of AM –as an END USER and SUPPLIER
Pajazit Avdovic | SE GP I SV TI AM ID
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
Process steps for metal Additive manufacturing
Reversed engineering
Customer
Design Technical
preparation
Additive
Manufacturing
Physical part supply
Virtual Part
Storage/Capacity
Existing component
with 3D model
Design for AM
Optimization
Existing component without 3D
model
Preparation for manufacturing process of part
Manufacturingof part
Supply of part
Preparation for manufacturing process of part
Manufacturingof part
Supply of partDesign for AM
Pre-qualification process
Reversed Engineering
by 3D scanning*
Component Validation
Reversed Engineering
by 3D scanning*
Issue Analysis
Component Validation
Preparation for manufacturing process of part
Manufacturingof part
Supply of partDesign for AM
Pajazit Avdovic | SE GP I SV TI AM ID
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
Siemens Energy and University cooperation in AM area
Digitalization
Robotics
Application
Processes
Material
Generic; Application; Advanced
Member:
▪ ARENA
▪ CAM2
▪ DMRC
▪ TTC
Cooperation with:
❖ Universities
❖ Research Institutes
❖ Companies >50
Participating
➢ more than 20 ongoing projects/year (Sweden)
➢ EU funded projects
Pajazit Avdovic | SE GP I SV TI AM ID
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Lattice structure and Topology optimization-Integration with CAD geometry (Niclas Strömberg, Ph.D., Docent-Örebro University)
The projects as a result of cooperation with universities and research institutes
Material Development: microstructures of 316L
3D Visualisation of Powderbed images
Original captured image Cropped and processed Generated 3D volume
Pajazit Avdovic | SE GP I SV TI AM ID
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FBG Infrared camera
0
Calculation model
0
0
Optical fiber based
on
Fiber Bragg Grating
(FBG) technology
The projects as a result of cooperation with universities and research institutes
Inspection of component by Using of CT
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The projects as a result of cooperation with universities and research institutes
Several aspects related to
AM automation
• Analyze and create directives
and guidelines for what and in
which situations AM
production should be
automated.
• Adapt the automation based on
the need, not the need based
on the automation of AM
• Automation level of AM, what
is the company's policy ?
Collaborative robots for cleaning of machines chamber
Pajazit Avdovic | SE GP I SV TI AM ID
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
Removing barriers to industrializing additive manufacturing
(Source: TechClarity, 2017)
60
%
of Companies believe 3D is the best technology to help competitiveness
52 of Companies are prototyping today using additive manufacturing
78 of Companies consider additive manufacturing during the concept plane
58
%
of power users say they are looking to additive manufacturing to
accelerate their product development.
90 of companies consider 3D printing a competitive advantage.
(Source: Sculpteo, 2017)
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
How to succeed with 3D printing - Critical success factors
Some operations deleted
Some operations added
Material development
Health & Environment
Expensive machinery
Manufacturing time
Pre and post processing
Management's trust in the method
Funding
Designers think DFAM
Right detail to Additive Manufacturing
The right material
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
3D printed parts are already in use at Nuclear Power Plant Krško, Slovenia
First 3D printed water pump impeller is successful
commercial operation at nuclear power plant
Customers benefits:
• Obsolete parts can be re-produced
• Significant lead time reduction
• Parts on demand
Pajazit Avdovic | SE GP I SV TI AM ID
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
Project nr 2 in area of NUC
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2020-09-23 Siemens Energy is a registered trademark licensed by Siemens AG.
Thanks you for the attention!
Published by Siemens Energy
Pajazit Avdovic PhD
Innovation Manager at Additive Manufacturing
Slottsvagen 2-6
612 83 Finspång
Sweden
Phone: +46 (0) 122 81479
Fax: +46 (122) 88712
Mobile: +46 702 85 82 35
E-mail: pajazit.avdovic@siemens.com
siemens-energy.com
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